Anion exchange membranes and process for making

ABSTRACT

Embodiments of the present invention provide for anion exchange membranes and processes for their manufacture. The anion exchange membranes described herein are made the polymerization product of at least one functional monomer comprising a tertiary amine which is reacted with a quaternizing agent in the polymerization process.

This application claims the benefits of U.S. provisional application61/393,715 filed on Oct. 15, 2010.

FIELD

Embodiments of the present invention provide for anion exchangemembranes and processes for their manufacture.

BACKGROUND

Anion exchange membranes transport anions under an electrical orchemical potential. A anion exchange membranes will have fixed positivecharges and mobile positively charged anions. Ion exchange membraneproperties are controlled by the amount, type and distribution of thefixed ionic groups. Quaternary and tertiary amines respectively producethe fixed positive charged groups in strong and weak base anion exchangemembranes.

Among the most important applications of ion exchange membranes aredesalination of water by electrodialysis (ED), as a power generatingsources in reverse electrodialysis and as separators in fuels cells.Other applications include recovery of metal ions in the electroplatingand metal finishing industries and various applications in the food andbeverage industry.

Electrodialysis desalinates water by transferring ions and some chargedorganics through paired cation and anion selective membranes under themotive force of a direct current voltage. An ED apparatus consists ofelectrically conductive and substantially water impermeable cationselective and anion selective membranes arranged as opposing walls of acell. Adjacent cells form a cell pair. Membrane stacks consist of many,sometime hundreds of cell pairs, and an ED systems may consist of manystacks. Each membrane stack has a DC (direct current) anode at one endof the stack and a DC cathode at the other end. Under a DC voltage, ionsmove to the electrode of opposite charge.

A cell pair consists of two types of cells, a diluting cell and aconcentrating cell. As an illustrative example, consider a cell pairwith a common cation exchange membrane wall and two anion exchangemembrane walls forming the two cells. That is, a first anion exchangemembrane and the cation exchange membrane form the dilute cell and thecation exchange membrane and a second anion membrane form theconcentrating cell. In the diluting cell, cations will pass through thecation exchange membrane facing the anode, but be stopped by the pairedanion exchange membrane of the concentrating cell in that directionfacing the cathode. Similarly, anions pass through the anion exchangemembrane of the diluting cell facing the cathode, but will be stopped bythe cation exchange membrane of the adjacent pair facing the anode. Inthis manner, salt in a diluting cell will be removed and in the adjacentconcentrating cells cations will be entering from one direction andanions from the opposite direction. Flow in the stack is arranged sothat the dilute and concentrated flows are kept separate and adesalinated water stream is produced from the dilute flow.

In the ED process, material commonly builds up at the membrane surfacein the direction of the electric field, which can, and usually doesreduce process efficiency. To combat this effect, Electrodialysisreversal (EDR) was developed and is the primary method of use presently.In EDR, the electrodes are reversed in polarity on a regular basis, forexample, every fifteen to sixty minutes. The dilute and concentrateflows are simultaneously switched as well, the concentrate becoming thedilute flow and vice versa. In this way fouling deposits are removed andflushed out.

Once the concentration in the dilution cells falls to lower than about2000 milligrams/liter (mg/l), electrical resistance is at a level thatpower demand becomes increasingly expensive. To overcome this, and to beable to produce high quality water, electrodeionization (EDI), sometimescalled continuous electrodeionization (CEDI) was developed. In thismethod the cells are filled with ion exchange media, usually ionexchange resin beads. The ion exchange media is orders of magnitude moreconductive than the solution. The ions are transported by the beads tothe membrane surface for transfer to the concentrate cells. EDI iscapable of producing purer water then ED at less power when the feedconcentration is reduced sufficiently.

ED processes for water desalination have advantages over RO. Theyrequire less pretreatment which will reduce operating costs. They willhave higher product water recovery and a higher brine concentration,i.e., there is less brine to dispose.

Univalent selective or monovalent selective membranes primarily transfermonovalent ions. Monovalent selective cation exchange membranesprimarily transfer sodium, potassium, etc. Likewise, monovalentselective anion membranes transfer ions such as chloride, bromide,nitrate etc.

Reverse osmosis (RO) dominates the production of fresh water fromseawater by membrane processes. While electrodialysis (ED) is used forbrackish water and waste water desalination, it is generally consideredtoo expensive for seawater use. In order to be competitive with RO, EDand EDR will require membrane resistance of less than 1 ohm-cm²,preferably less than 0.8 ohm-cm², and most preferably less than 0.5ohm-cm². Ion permselectivity of greater than 90%, more preferablygreater than 95%, and most preferably greater than 98% is desired. Themembrane has to have long service life, and be physically strong andchemically durable and be low cost.

Reverse electrodialysis (RED) converts the free energy generated bymixing the two aqueous solutions of different salinities into electricalpower. The greater the difference in salinity, the greater the potentialfor power generation. For example, researchers have studied RED usingDead Sea water and fresh or seawater. Researchers in Holland have mixedriver water entering the sea and seawater. RED membranes preferably willhave a low electrical resistance and a high co-ion selectivity and longservice life time, acceptable strength and dimensional stability and,importantly, low cost.

The polymer electrolyte membrane (PEM) is a type of ion exchangemembrane that serves both as the electrolyte and as a separator toprevent direct physical mixing of the hydrogen from the anode and oxygensupplied to the cathode. A PEM contains positively charged groups,usually sulfonic acid groups, attached or as part of the polymer makingup the PEM. Protons migrate through the membrane by jumping from onefixed positive charge to another to permeate the membrane.

PEM's requirements include chemical, thermal and electrochemicalstability, and adequate mechanical stability and strength when swollenand under mechanical stress. Other requirements include low resistance,low or preferably no methanol transport in direct methanol fuel cells(DMFC), and low cost.

Bipolar membranes are made of a cation exchange and an anion exchangemembrane laminated or bound together, sometimes with a thin neutrallayer between. Under an electric field water is split into H+ and OH⁻ions. The hydroxyl ions are transported through the anion exchangemembrane and the H⁺ ions through the anion exchange layer and will formbase and acid in the respective cells. Organic acids are also made usingbipolar membranes.

Development of ion exchange membranes requires an optimization ofproperties in order to overcome competing effects. Ion exchangemembranes for water desalination traditionally have had to meet fourmain characteristics to be considered successful. These are:

Low electrical resistance to reduce potential drop during operation andto increase energy efficiency

High permselectivity—that is, high permeability to counter-ions butapproximately impermeable to co-ions

High chemical stability—ability to withstand pH from 0 to 14 andoxidizing chemicals

Mechanical strength—The membrane must be able to withstand the stressesof being handled while being manufactured into a module or otherprocessing device. The membrane must also have good dimensionalstability in operation and not swell or shrink excessively when thefluid contacting it changes concentration or temperature.

Membrane developers have recognized that for a given chemistry used tomake an ion exchange membrane, a thinner membrane would give a lowerresistance and also allow more membrane area per unit volume of device.However, thinner membranes are more susceptible to dimensional changefrom environmental effects, such as changes in ionic concentration ofthe fluids contacting them or operating temperature changes. Moreover,to develop and produce defect-free membranes is more difficult for thecase of thinner membranes because there is less margin of error duringmembrane production as there is for thicker membranes where the membranethickness covers over defects that may occur in membrane formation.

DETAILED DESCRIPTION

International Application # PCT/US 10/46777 incorporated in its entiretyby reference describes a method of making ion exchange membranesproduced by polymerizing one or more monofunctional ionogenic monomerswith at least one multifunctional monomer in the pores of a poroussubstrate.

As described herein the inventor has found that by using functionalmonomers having a tertiary amine group with a quaternizing chemical,anion exchange membranes of low resistance high permeability and goodchemical resistance can be made. The quaternary ammonium functionalgroups are strongly basic and ionized to act over the pH range of 0 to13 allowing a broad operational range. Of particular utility are vinylcompounds having nitrogen containing rings.

Preferred tertiary amine monomers are vinylimidazole and vinylcarbazole.

The tertiary amine containing monomer is polymerized with at least onecrosslinking monomer and at least one quaternizing agent and one or morepolymerization initiators to form the ionogenic polymer in the pores ofthe porous substrate.

The tertiary amine containing monomer may be copolymerized with at leastone secondary functional monomer such as but not limited to;vinylbenzyltrimethylammonium chloride, trimethylammoniumethylmethacyrlic chloride, methacrylamidopropyltrimethylammoniumchloride, (3-acrylamidopropyl)trimethylammonium chloride,2-vinylpyridine, and 4-vinylpyridine, at least one crosslinking monomerand at least one quaternizing agent, and one or more polymerizationinitiators.

Furthermore, either of these methods may be done with at least one addednon-functional secondary monomer such as but not limited to; styrene,vinyl toluene, 4-methylstyrene, t-butyl styrene, alpha-methylstyrene,methacrylic anhydride, methacrylic acid, n-vinyl-2-pyrolidone,vinyltrimethoxysilane, vinyltriethoxysilane,vinyl-tris-(2-methoxyethoxy)silane, vinylidene chloride, vinylidenefluoride, vinylmethyldimethoxysilane, 2,2,2,-trifluoroethyl methacrylateallyamine, vinylpyridine, maleic anhydride, glycidyl methacrylate,hydroxyethylmethacrylate, methylmethacrylate, or ethylmethacrylate.

The at least one crosslinker is preferably divinylbenzene or ethyleneglycol dimethacrylate.

Optionally, at least one crosslinker may be chosen from propylene glycoldimethacrylate, isobutylene glycol dimethacrylate, Octa-vinyl POSS®(Hybrid Plastics, OL1160), Octavinyldimethylsilyi POSS® (HybridPlastics, OL1163), Vinyl POSS® Mixture (Hybrid Plastics, OL1170),OctaVinyl POSS® (Hybrid Plastics, OL1160), Trisilabolethyl POSS® (HybridPlastics, SO1444), Trisilanolisobutyl POSS® (Hybrid Plastics, O1450),Trisilanolisooctyl POSS® (Hybrid Plastics, SO1455), Octasilane POSS®(Hybrid Plastics, SH1310), Octahydro POSS® (Hybrid Plastics, SH1311),epoxycyclohexyl-POSS® cage mixture (Hybrid Plastics, EP04080),glycidyl-POSS® cage mixture (Hybrid Plastics, EP0409), methacryl POSS®Cage Mixture (Hybrid Plastics, MA0735), or Acrylo POSS® Cage Mixture(Hybrid Plastics, MA0736).

Solvents found useful are N-propanol and dipropylene glycol. Similarhydroxy containing solvents, such as alcohols, for example isopropanol,butanol; diols such as various glycols, or polyols, such as glycerinemay be useful in some cases. Additionally aprotic solvents such asN-methylpyrrolidone and dimethylacetamide may be used. These are givenas examples, not to be limiting to a practitioner. Dipropylene glycol isa preferred solvent.

Free radical initiators useful for the present invention include, butare not limited to; benzoyl peroxide (BPO), ammonium persulfate,2,2′-azobisisobutyronitrile (AIBN),2,2′-azobis(2-methylpropionamidine)dihydrochloride,2,2′-Azobis[2-(2-imidazolin-2y1)propane]dihydrochloride,2,2′-Azobis[2-(2-imidazolin-2-yl)propane] and dimethyl2,2′-azobis(2-methylpropionate).

A person skilled in the art of membrane development and manufacturingwill realize that this convenient laboratory method can be adapted toother laboratory scaled methods and may be scaled up to continuousmanufacturing.

For example, the substrate pore filling or saturation may be done at aslightly elevated temperature (>40° C.) to reduce air solubility, orthis step could be done after a mild vacuum treatment of the substratesample submerged in the formulation solution. Substrate samples may bepresoaked and then placed on the polyester or similar sheet and coveredwith a covering sheet and smoothed out to remove air bubbles. Severalpresoaked pieces may be layered and then placed on the polyester orsimilar sheet and covered with a covering sheet and smoothed out toremove air bubbles.

Rather than heating in an oven, the saturated substrate sandwich may beplaced on a heated surface at a temperature sufficient and for a timenecessary to initiate and complete polymerization. Alternate methods forinitiation of the polymerization reaction may be used. Ultraviolet lightor ionizing radiation, such as gamma radiation or electron beamradiation may be used to initiate the polymerization reaction.

Low resistance reduces the electrical energy required to desalinate andlowers operating cost. Specific membrane resistance is measured inOhm-centimeters (Ωcm). A more convenient engineering measure is arearesistance, Ohm-cm² (Ωcm²). Area resistance may be measured by using acell having two electrodes of known area, platinum or black graphite aretypically used, with the membrane sample of known area between them inan electrolyte solution. The electrodes do not touch the membrane.Membrane resistance is estimated by subtracting the electrolyteresistance without the membrane from the test result with the membranein place. The resistance may also be measured by determining a voltagevs. current curve in a cell having two well stirred chambers separatedby the membrane. A calomel electrode measures the potential drop acrossthe membrane. The slope of the potential drop vs. current curves, whichmay be obtained by varying voltage and measuring current.Electrochemical impedance may also be used. In this method, alternatingcurrent is applied across the membrane. Measurement at a singlefrequency gives data relating to electrochemical properties of themembrane. By using frequency and amplitude variations, detailedstructural information may be obtained. Herein, resistance will bedefined by the methods described in the Experimental section.

Permselectivity refers to the relative transport of counterions toco-ions during electrodialysis. For an ideal cation exchange membraneonly positively charged ions would pass the membrane, giving apermselectivity of 1.0. Permselectivity is found by measuring thepotential across the membrane while it separates monovalent saltsolutions of different concentrations. The method and calculations usedherein are described in the Experimental section.

To meet these initial goals the inventors developed a type of compositeion exchange membrane in which a cross-linked polymer having chargedionic groups attached is contained in the pores of a microporousmembrane substrate. The porous membrane substrate is preferably lessthan about approximately 155 microns thick, more preferably less thanabout approximately 55 microns thick.

Substrate membranes having porosity greater than about 45% arepreferred, with those having porosities greater than about 60% morepreferred. In the most preferred embodiments, the substrate membraneshave porosities greater than about 70%. Preferred substrate membraneshave a rated pore size of from about approximately 0.05 microns to aboutapproximately 10 microns, with a more preferred range of from aboutapproximately 0.1 microns to about approximately 1.0 microns. Mostpreferred porous substrates have a rated pore size of from aboutapproximately 0.1 microns to about approximately 0.2 microns.

Microporous membrane supports may be manufactured from polyolefins,polyolefin blends, polyvinylidene fluoride, or other polymers. A classof preferred substrates comprises thin polyolefin membranes manufacturedprimarily for use as battery separators. A more preferred substrateclass are thin battery separators manufactured from ultrahigh molecularweight polyethylene (UHMWPE).

To produce the desired ion exchange membranes, the inventors developed amethod of placing the crosslinked charged polymer in the pores of thesubstrate by polymerizing the crosslinked polymer in these pores. Themethod involved saturating the porous substrate with a solution ofcharged monomer, multifunctional monomer, (e.g., a crosslinking agent)and polymerization initiator. Herein we use the term ionogenic monomerto mean a monomer species having at least one charged group covalentlyattached. The charged group can be positively charged or negativelycharged. In an embodiment, the crosslinked polymer was produced bypolymerizing a multifunctional charged monomer. The Polymerization wasinitiated by heat or by UV light, preferably with a polymerizationinitiator such as a free radical initiator. Monofunctional monomers aremonomers which have a single site for carrying forward thepolymerization reaction. Multifunctional monomers have more than onepolymerization reaction site and so can form networked or crosslinkedpolymers.

The following laboratory method was used to investigate formulation andprocess effects by producing small coupons for resistivity andpermselectivity testing. Porous membrane substrate 43 mm diametercoupons were die cut. Somewhat larger discs (50 mm or 100 mm diameter)of transparent polyester sheets were also die cut. A 105 mm aluminumweighing boat was typically used to hold a set of coupons. The couponswere sandwiched between two polyester film discs. First, substratecoupons were thoroughly wetted with a monomer solution to make up a testsample. This was done by adding the formulated solution to the aluminumboat, and immersing a polyester film disc with a substrate couponlayered on it into the solution so that the porous support is saturated.The saturated support was then removed from the monomer solution andplaced on a piece of polyester film. Air bubbles were removed from thecoupon by, for example, smoothing or squeezing the coupon with aconvenient tool, such as a small glass rod, or by hand. A secondpolyester disc was then layered on top of the first coupon and smoothedto have complete surface contact between the coupon and the lower andupper polyester film layers. A second porous substrate was then layeredon the upper polyester film and the saturation, smoothing and additionof a over layer of polyester film repeated to give a multilayer sandwichof two coupons and three protective polyester film layers. A typicalexperimental run would have a multilayered sandwich of 10 or moresaturated substrate coupon layers. The rim of the aluminum boat can becrimped down to hold the disc/coupon assembly if required.

The boat and assembly were then placed in a sealable bag, typically azip-lock polyethylene bag and a low positive pressure of inert gas,usually nitrogen, added before sealing the bag. The bag containing theboat and coupon assembly is placed into a oven at 80° C. for up to about60 minutes. The bag is then removed and cooled, and the now reacted ionexchange membrane coupons are placed in 0.5N NaCl solution at 40° C.-50°C. for at least 30 minutes, with a soak in NaCl solution of up to 18hours being found satisfactory.

Experimental Examples

The following examples are meant to illustrate the extent of effortexpended in developing the subject membranes. The finding resulted inshowing that ion exchange membranes having the desired properties couldbe made and that improvements are possible with further experimentation.These results are meant to be illustrative and to indicate developmentaldirections to those skilled in the art of membrane development andassociated arts and not to be limiting as to the extent of the matterdisclosed herein.

Properties and suppliers of the supports used are given in Table 1below.

TABLE 1 Substrates Used Porous Substrates Rated Trade pore ThicknessPorosity name Manufacturer Material Size microns % APorous APorous HDPE0.1 52 68 H6A Billerica MA APorous HDPE 0.1 84 77 S14 Ahlstrom WallTownship, polyester 200 (Hollytex) New Jersey Teklon Entek UHMWPE 32 48HPIP32 Lebanon, OR Delpore Delstar meltblown 6002 Middleton DE DelstarDelstar Stratex Middleton DE 3.6SL-G Novatexx Freudenberg Spunlace 5582413 Hopkinsville, KY polyester Celgard CELGARD pp EZ2090 Charlotte NCCelgard CELGARD pp 32 45 EZ2590 Charlotte NC Solupor Lydall FiltrationUHMWPE 0.5 115 83% 16P5A Rochester NH Solupor Lydall Filtration UHMWPE0.9 120 85% 16P10A Rochester NH

Representative porous substrates were tested for baselinepermselectivity and resistance. They are pre-washed usingisopropanol-ethanol and D.I. water each for 5 minutes, then they wererinsed by 0.5 N NaCl (aq) 3 times testing Table 2 below shows theresults of area resistance in Ohm cm² of AEM thus made and theirapparent permselectivity %:

TABLE 2 Characteristics of selected substrates Apparent DescriptionR(ohm cm²) Permselectivity % Teklon HPIP 0.593 57.24 Solupor 16P1OA2.192 57.38 Aporous H6A 0.152 57.54 Celgard EZ-2590 0.788 57.54 CelgardEZ-2090 1.159 57.38

Example 1

In a 4 oz jar with 17.08 g of 1-vinylimidazole, 9.14 g of vinylbenzylchloride, 5.39 g of divinylbenzene (80%), 16.61 g of benzyl chloride,20.65 g of dipropylglycol (DPG) and 0.40 g Vazo-64 were combined withstirring. A clear brown solution formed immediately. Substrates Solupor16P10A, 16PO5A, Teklon, Aporous S14, Celgard EZ2090, EZ2590, Novatexx2431ND, Delstar 6SLG, Ahlstrom 3329, Delpore DP3924-80PNAT, Delpore6002-20PNAT were soaked the solution for 1 hour to assure complete porefilling. Then they were sandwiched between Mylar disks, air bubblesbetween Mylar disks removed by pressure and the sandwiched substratesplaced in an aluminum weighting dish. The dish was loaded into a Ziploc®bag, the bag pressurized with nitrogen gas and placed in an 80° C. ovenfor 1 hour. The membrane coupon thus made was placed in 0.5 N NaCl(aq)for conditioning. Table 3 below shows the results of area resistance inOhm cm² of AEM thus made and their apparent permselectivity %:

TABLE 3 R(ohm Apparent Substrates cm²) Perms % Ahsltrom 3329 200 micronthick 31.75 92.62 Aporous S14 2.145 93.11 Celgard X021 (EZ2590)  32micron thick 2.68 92.78 Teklon HPIP  32 micron thick 5.00 94.26 Solupor16P05A 115 micron thick 2.55 92.95 Solupor 16P1OA 200 micron thick 3.5592.62 Delpore6002-20PNAT 3.64 89.01 nonwoven Novatexx 2431ND 7.51 73.03Delstar 6SLG nonwoven 12.62 87.70 Celgard EZL2090 3.29 90.52Delpore6002-20PNAT 2.35 89.86 nonwoven 2nd coupon

Example 2

In a 4 oz jar with 15.71 g of 1-vinylimidazole, 25.47 g of vinylbenzylchloride, 13.25 g of DPG and 0.42 g Vazo-64 were combined with stirring.A clear brown solution formed immediately. Substrates Solupor 16P10A,16PO5A and Teklon HPIP, were soaked the solution for 1 hour to assurecomplete pore filling.

Then they were sandwiched between Mylar disks, air bubbles between Mylardisks removed by pressure and the sandwiched substrates placed in analuminum weighting dish. The dish was loaded into a Ziploc bag, the bagpressurized with nitrogen gas and placed in an 80° C. oven for 1 hour.The membrane coupon thus made was placed in 0.5 N NaCl(aq) forconditioning. Table 4 below shows the results of area resistance in Ohmcm² of AEM thus made and their apparent permselectivity %.

Also shown are commercially available ion exchange membranes AMX and CMXfrom Astom-Japan. Both are 125 microns thick.

TABLE 4 R(ohm Apparent Description cm²) Permselectivity % Teklon HPIP 32 micron thick 6.55 91.64 Solupor 16P1OA 120 micron thick 3.54 92.62Astom AMX (anion exchange membrane) 3.13 96.07 Astom CMX (cationexchange membrane 2.37 106.50

The results in tables 3 and 4 show that membranes made by the inventivemethod has approximately equivalent properties to much thickermembranes. Thinner membranes allow for increased number of membranes permodule or housing volume and therefore more productivity per unitvolume.

Example 3

In a 4 oz jar with 17.12 g of 1-vinylimidazole, 20.00 g of vinylbenzylchloride, 16.00 g of benzyl chloride, 11.02 g of DPG and 0.51 g Vazo-64were combined with stirring. A clear brown solution formed immediately.Substrates Solupor 16P10A, and Teklon (HPIP, 32 micron, single layer)were soaked in the solution for 1.5 hour to assure complete porefilling.

Then they were sandwiched between Mylar disks, air bubbles between Mylardisks removed by pressure and the sandwiched substrates placed in analuminum weighting dish. The dish was loaded into a Ziploc® bag, the bagpressurized with nitrogen gas and placed in an 80° C. oven for 40minutes. The membrane coupon thus made was placed in 0.5 N NaCl (aq) forconditioning. Table 3 below shows the results of area resistance in Ohmcm² of AEM thus made and their apparent permselectivity %.

Also shown is a commercially available ion exchange membranes AMX fromAstom-Japan. Its thickness is 125 micron.

TABLE 3 Description R(Ω cm²) Apparent Teklon HPIP 32 micron 2.33 95.09Solupor 16P10A 120 micron 2.17 95.57 Astom AMX (anion 2.73 94.55exchange membrane)

Example 4

In a 4 oz jar with 8.55 g of 1-vinylimidazole, 10.01 g of vinylbenzylchloride, 1.02 g of divinyl benzene (80%), 12.01 g of benzyl chloride,5.61 g of DPG and 0.31 g Vazo-64 were combined with stirring. A clearbrown solution formed immediately. Substrates Solupor 16P10A, and TeklonHPIP (single layer), Aporous H6A and Celgard EZ2590, were soaked in thesolution for 75 minutes to assure complete pore filling.

Then they were sandwiched between Mylar disks, air bubbles between Mylardisks removed by pressure and the sandwiched substrates placed in analuminum weighting dish. The dish was loaded into a Ziploc® bag, the bagpressurized with nitrogen gas and placed in an 80° C. oven for 47minutes. The membrane coupon thus made was placed in 0.5 N NaCl (aq) forconditioning. Table 4 below shows the results of area resistance in Ωcm²of AEM thus made and their apparent permselectivity %.

Also shown is a commercially available ion exchange membranes AMX fromAstom-Japan. Its thickness is 125 micron.

TABLE 4 R(Ohm Apparent Description cm²) Permselectivity % Teklon HPIP32micron 4.24 95.21 Solupor 16P10A, 120 micron 2.62 94.71 Aporous H6A,52 micron 2.55 95.04 Celgard EZ2590, 27 micron 1.98 94.55 Astom AMX(anion 2.73 94.55 exchange membrane)

Example 5

In an 8 oz jar with 30.7 g of 1-vinylimidazole, 17.2 g of vinylbenzylchloride, 42.5 g of benzyl chloride, 11.8 g Divinylbenzene (80%), 27.0 gof DPG and 0.41 g Vazo-64 were combined with stirring. A clear brownsolution formed immediately. Coupons of substrates Solupor 16P05A weresoaked in the solution for 2 hour to assure complete pore filling.

Then they were sandwiched between Mylar disks, air bubbles between Mylardisks removed by pressure and the sandwiched substrates placed in analuminum weighting dish. The dish was loaded into a Ziploc® bag, the bagpressurized with nitrogen gas and placed in an 80° C. oven for 1 hour.The membrane coupon thus made was placed in 0.5 N NaCl (aq) forconditioning. Table 5 below shows the results of area resistance in Ωcm²of AEM thus made and their apparent permselectivity %.

Also shown is a commercially available ion exchange membranes AMX fromAstom-Japan. Its thickness is 125 micron.

TABLE 5 Apparent Description R(Ohm cm²) Permselectivity % % Solupor16P05A, 2.60 95.00 115 micron Astom AMX (anion 3.10 95.08 exchangemembrane)

Example 6

In a 20 ml vial with 3.43 g of 1-vinylimidazole, 3.0 of vinylbenzylchloride, 1.0 gm EP0409 (Hybrid Plastics, glycidyl-POSS® cage mixtureCAS #68611-45-0), 3.2 g of benzyl chloride, 2.20 g of DPG and 0.10 gVazo-64 were combined with stirring. A clear brown solution formedimmediately. Coupons of substrate Solupor 16P10A were soaked in thesolution for 0.5 hour to assure complete pore filling.

Then they were sandwiched between Mylar disks, air bubbles between Mylardisks removed by pressure and the sandwiched substrates placed in analuminum weighting dish. The dish was loaded into a Ziploc® bag, the bagpressurized with nitrogen gas and placed in an 90° C. oven for 1 hour.The membrane coupon thus made was placed in 0.5 N NaCl (aq) forconditioning. Table 6 below shows the result of area resistance in Ohmcm² of AEM thus made and their apparent permselectivity %.

Also shown is a commercially available ion exchange membranes AMX fromAstom-Japan having a thickness is 125 micron.

TABLE 6 R(Ohm Apparent Description cm²) Permselectivity % % Solupor16P10A, 2.59 93.92 120 micron Astom AMX (anion 2.42 93.59 exchangemembrane)

Experiment Procedures for Membrane Area Resistivity and ApparentPermselectivity Characterization

The membrane resistance and counter ion transport number(permselectivity) can be measured using an electrochemical cell. Thisbench top experiment provides us with a very effective and quickexperiment using a small piece of sample. The equipment and procedureare described here.

Experiment Preparation (1) Solartron 1280 Electrochemical MeasurementUnit

The Solartron 1280 electrochemical measurement unit enables us to applya current between the two platinum electrodes on the two sides of thecell and to measure the voltage drop across membrane. It has 4connectors: work electrode (WE), counter electrode (CE), Referenceelectrodes (RE1 and RE2). The CE and WE are used to apply current and RE1 and RE2 to measure the voltage drop.

(2) Reference Electrodes

Reference electrodes (see the insert in FIG. 1) used for membranecharacterization are made in R&D lab. ¼″ glass tubing is softened, thenbent and drawn to the form shown. A porous plug is inserted in the tipto control solution flow to a low rate.

Silver/silver chloride wire is freshly made for each day's testing. Acurrent of 2-3 mA was supplied and controlled by a power supplier and anampere meter to a platinum wire cathode and silver wire anode immersedin a 0.1N HCl solution. After several minutes, the sliver wire starts toturn black, indicating the formation of AgCl layer on the surface. Thesolution used inside the reference electrode tubing is 1.0M KClsolution. Since the solution will leak through the porous tip, constantaddition of KCl is a necessary (˜every 20 min) during experiment.

(3) Membrane Test Cell

FIG. 1 shows the detailed electrochemical testing cell construction usedfor the experiment to measure resistance and counter ion permselectivityof the membrane. The membranes are cut into disc using a die cutter. Thereference electrodes are used to monitor the voltage drop across thetesting membrane and the 2 platinum discs are used to provide a currentthrough the membrane. The cylindrical path of the cell has a crosssection area of 7.0 cm²

(4) Solutions

All the solutions need to be prepared with quantitative level asindicated by their significant figures. These includes 0.500N NaCl, 1.0NHCl and 1.0N NaOH (caustic, using plastic container or volumetricflask). The 0.5N Na₂SO₄ is used to feed the electrode compartmentswithout evolution of chlorine gas.

3-III. Measurement Procedures (1) Resistance Measurement

Resistance here refers to area resistance Ω-cm². The measurementcontains 3 steps.

-   -   (a) Set up electrode positions: Prior to a measurement, the        reference electrode horizontal positions are set. To set        reference electrode position, a rigid plastic disc is used as a        stand-in for the membrane. Each reference electrode is adjusted        to just touch the plastic disc and their position fixed by two        set screws.    -   (b) Measure the solution conductivity: The plastic disc was then        removed and the two reference electrodes moved to 1.0 cm apart        by removing the two 0.50 mm plastic blocks. The voltage drop        between the two reference electrodes is recorded at an applied a        current (−10-50 mA) by the Solartron 1280. The distance of the 2        reference electrodes (1.00 cm here), the current density (10.00        mA) and voltage (to 0.1 mV precision) used to obtain the        conductivity of the solution (0.50 N NaCl typically).    -   (c) Measuring membrane resistance: The membrane sample is then        placed by the sample slider and the voltage and current measured        again. The resistance of membrane is the total resistance less        the solution resistance measured in procedure (b)

(2) Counter Ion Permselectivity (Transport Number)

The measurement procedures are:

-   -   (a) Reference electrode position is set as described by part(a)        of Resistance measurement. The reference electrodes position may        be approximate since the voltage measured in this test is        theoretically independent of the distance, but it is recommended        that the position be located as reproducibly as possible.    -   (b) Solutions: After emplacing the sample membrane with the        slider, pour 0.500N NaCl solution in the right part of the cell        separated by the testing membrane and 0.250 NNaCl on the left        side of the cell.    -   (c) Measuring the voltage: the voltage was measured (without        applying current) using a voltage meter attached to the platinum        electrodes and data were entered the spreadsheet to obtain        counter ion permselectivity.

3-IV. Sample Calculations:

C=conductivity (siemens/cm)

ρ=resistance (ohms/cm)

R=resistivity (ohm-cm² or Ω·cm²)

A=area (cm²)

U, V=measured voltage (mV)

I=measured current (mA)

L=distance between reference electrodes

-   (1) Conductivity of the 0.500 M NaCl at 10.00 mA current and 33.1 mV    measured for a reference electrode distance of 1.00 cm, the    conductivity of solution:

$C = {\frac{1}{\rho} = {\frac{L}{R} = {\frac{L}{\frac{U}{I} \times A} = {\frac{1.00\mspace{14mu} {cm}}{\frac{33.1\mspace{14mu} {mV}}{10.0\mspace{14mu} {mA}} \times 7.00\mspace{14mu} {cm}^{2}} = {0.0432\mspace{20mu} S\text{/}{cm}}}}}}$

-   (2) Area resistance of the membrane calculation needs to subtract    the solution resistance. For a CMX membrane with a measured    potential of 38.0 mV, the area resistance is:

$R = {{\frac{( {38.1 - 33.1} )\mspace{14mu} {mV}}{10.0\mspace{14mu} {mA}} \times 7.00\mspace{14mu} {cm}^{2}} = {3.42\mspace{14mu} {\Omega \cdot {cm}^{2}}}}$

-   (3) Permselectivity (transport number) of anion(+) or anion(−)    membrane T_(±) is obtained by:

$V = {( {{2\; T_{\pm}} - 1} )\frac{RT}{F}\ln \; \frac{a_{L}}{a_{R}}}$

Which rearranges to;

${2T_{\pm}} = {1 + {{VF}\text{/}{RT}\; ( {\ln \; \frac{a_{R}}{a_{L}}} )}}$

Where V is measured voltage by the reference electrodes, R is gasconstant (8.314 Joule·K⁻¹·mole⁻¹) T is Kelvin temperature of solution, Fis Faraday constant (96480 coulomb/mole) and a_(R) and a_(L) areconcentration (activity format) of the solution on the two sides of themembrane in the cell.

1. An anion exchange membrane comprising: a microporous membrane supporthaving a porous first side, a porous second side, and a continuousporous structure extending from the first side to the second side; and acrosslinked ion transferring polymer filling the continuous porousstructure, the polymer formed in the continuous porous structure andcomprising; the polymerization product of a monomeric solution having atleast one functional monomer comprising a tertiary amine, at least onecrosslinking monomer, at least one quaternizing agent, and at least onepolymerization initiator.
 2. The anion exchange membrane of claim 1,wherein the at least one functional monomer is selected from the groupconsisting of vinylimidazole and vinylcarbazole.
 3. The anion exchangemembrane of claim 1, wherein the at least one crosslinking monomer isselected from the group consisting of: divinylbenzene, ethylene glycoldimethacrylate, vinylbenzyl chloride, dichloroethane, propylene glycoldimethacrylate, isobutylene glycol dimethacrylate, C₁₆H₂₄O₁₂Si₈,C₃₂H₇₂O₂₀Si₁₆, (CH₂CH)_(n)(SiO_(1.5))_(n) wherein n=8, 10, or 12,C₁₄H₃₈O₁₂Si₇, C₂₈H₆₆O₁₂Si₇, C₅₆H₁₂₂O₁₂Si₇, C₁₆H₅₆O₂₀Si₁₆, H₈O₁₂Si₈,(C₈H₁₃O)_(n)(SiO_(1.5))_(n) wherein n=8, 10, 12,(C₆H₁₁O₂)_(n)(SiO_(1.5))_(n) wherein n=8, 10, or 12,(C₇H₁₁O₂)_(n)(SiO_(1.5))_(n) wherein n=8, 10, or 12, and(C₆H₉O₂)_(n)(SiO_(1.5))_(n) wherein n=8, 10, or
 12. 4. The anionexchange membrane of claim 1, wherein the at least one quaternizingagent is selected from the group consisting of benzyl chloride, benzylbromide, vinyl benzyl chloride, dichloroethane, or methyl iodide.
 5. Theanion exchange membrane of claim 1, wherein the at least onepolymerization initiator is selected from the group consisting oforganic peroxides, 2,2′azobis[2,[2-imdazolin-2-yl]-propane]dihydrochloride,α,α′-azoisobutyronitrile,2,2′-azobis[2-methylpropioaminidine]dihydrochloride, 2,2′azobis[2,[2-imdazolin-2-yl]propane], or dimethyl-2,2′azobis[2-methylpropionate].
 6. The anion exchange membrane of claim 5,wherein the organic peroxide is benzoyl peroxide.
 7. The anion exchangemembrane of claim 1, wherein the monomeric solution further comprises atleast one polymerization inhibitor.
 8. The anion exchange membrane ofclaim 7, wherein the at least one polymerization inhibitor is selectedfrom the group consisting of 4-methoxyphenol and 4-tert-butyl catechol.9. The anion exchange membrane of claim 1, wherein the microporoussupport comprises polypropylene, high molecular weight polyethylene,ultrahigh molecular weight polyethylene or polyvinylidene fluoride. 10.The anion exchange membrane of claim 1, wherein a thickness of themicroporous porous support is greater than about 55 microns and lessthan about 155 microns.
 11. The anion exchange membrane of claim 1,wherein a thickness of the microporous porous support is greater thanabout 20 microns and less than about 55 microns.
 12. A process forproducing an ion exchange membrane, comprising: choosing a suitableporous substrate having a porous first side, a porous second side, and acontinuous porous structure extending from the first side to the secondside; saturating the porous substrate with a monomeric solutioncomprising at least one functional monomer comprising a tertiary amine,at least one crosslinking monomer, at least one quaternizing agent, andat least one polymerization initiator; removing excess solution from thesubstrate while leaving the continuous porous structure filled withsolution; and initiating polymerization to form a crosslinked anionexchange polymer in the continuous porous structure of the substrate.13. The process of claim 12, wherein the at least one functional monomeris selected from the group consisting of vinylimidazole andvinylcarbazole.
 14. The process of claim 12, wherein the at least onecrosslinking monomer is selected from the group consisting of:divinylbenzene, vinylbenzyl chloride, dichloroethane, anoctaglycidyl-polyhedral oligomeric silsequioxane, and ethylene glycoldimethacrylate.
 15. The process of claim 12, wherein the at least onequaternizing agent is selected from the group consisting of benzylchloride, vinyl benzyl chloride, dichloroethane, or methyl iodide. 16.The process of claim 12, wherein the at least one polymerizationinitiator is selected from the group consisting of organic peroxides,2,2′-azobis[2,(2-imidazolin-2-yl)-propane]dihydrochloride, a,a′azoisobutyronitrile,2,2′-azobis(2-methylpropioaminidine)dihydrochloride,2,2′-azobis[2,(2-imidazolin-2-yl)-propane], and dimethyl2,2′-azobis(2-methylpropionate).
 17. The process of claim 16, whereinthe organic peroxide is benzoyl peroxide.
 18. The process of claim 12,wherein the monomeric solution further comprises at least onepolymerization inhibitor.
 19. The process of claim 18, wherein the atleast one polymerization inhibitor is selected from the group consistingof 4-methoxyphenol and 4-tert-butyl catechol.
 20. The process of claim12, wherein the microporous support comprises polypropylene, highmolecular weight polyethylene, ultrahigh molecular weight polyethyleneor polyvinylidene fluoride.
 21. The process of claim 12, wherein athickness of the microporous porous support is greater than about 55microns and less than about 155 microns.
 22. The process of claim 12,wherein a thickness of the microporous porous support is greater thanabout 20 microns and less than about 55 microns.
 23. The anion exchangemembrane of claim 1, the membrane having a resistivity of less thanabout 2.5 Ohm-cm².
 24. The anion exchange membrane of claim 1, themembrane having an apparent permselectivity of at least about 90%. 25.The anion exchange membrane of claim 24, the membrane having an apparentpermselectivity of at least about 95%.